Structural panel member



Feb. 16, 1960 Filed 00:21:.` 16, 1956 K. W. coUsE EVAL STRUCTURAL PANEL MEMBER 5 sheets-sheet 1 J ffy Feb. 16, 1960 K, wl CQUSE ET AL 2,924,858

STRUCTURAL PANEL MEMBER 5 Sheets-Sheet 2 Filed Oct. 16, 1956 Feb. 16, 1960 K- w, CQUSE ETAL 2,924,858

STRUCTURAL PANEL MEMBER 5 Sheets-Sheet 3 Filed Oct. 16. 1956 x5.: f y C f Feb. 16,1960 K. w. CQUSE mL 2,924,858

STRUCTURAL PANEL MEMBER Filed Oct. 16, 1956 1 5 Sheets-Sheet 4 Feb. 16, 1960 K W CQUSE ETAL STRUCTURAL rPANEL. MEMBER 5 Sheets-Sheet 5 Filed Oct. 16, 1956 2,924,858 STRUCTURAL PANEL MEMBER `Kibbey W. Couse and Robert M. Sutphen, Newark, NJ.,

1 as signors to Couse Manufacturing, Inc., Newark, NJ.,

a corporation of New Jersey Application October 16, 1956, Serial No. 616,298

i curing. (cl. zia-1s) i invention yrelates toa structural panel member .and more particularly to atriangular-shaped panel member having elongated grooves along the perimeter thereof which are adapted to receive binder members for connecting the panel member to adjoining panel members of substantially identical construction.

The structural panel -rnembers, or building blocks, of our invention are particularly adapted for use in the construction of portable shops, huts and other buildings :wherein they are used to form the component parts jthereof; i.e. the floors, walls, ceilings, roofs and the like.

While, in general, structural panel members may be of any desired size or shape, a right isosceles triangular-` shaped panel member is preferred wherein the short, equal jleugth, sides thereof are approximately seven (7) feet in length. A pair of such triangular-shaped panel members joined along their diagonal edges provide a com- :posite panel member seven (7) feet square, which may constitute an entire floor or roof of a building, or a portion thereof, if desired. `Each panel member is provided with a plurality of -elongated grooves, having enlarged bottom portions.

Such grooves are located oneach edge of the panel member, and on both faces thereof a spaced distance from,

pand parallel to, the edges of the panel member. In addijtion to the grooves, each side of the triangular-shaped .structural panelmember is provided with at least one notched, or recessed, portion which extends past the edge and both faces of the panel member. Each notch, or

frecressed, portion comprises three lcut-out sections; one on the edge and one on the opposite faces of the panel rnember.. The depth of the notches as substantially 4.equal to rthe depth of the associated edge and face groove.

" structural'panel member for use in forming building structureA components. I

A-n object of this invention is the "provision of a build- 'ingbloclg or structural panel rnembenwhich is in the ,shape of an isosceles right triangle and which is provided with elongated grooves alonghthe perimeter thereof, and l notched means wherein binder members may be inserted 'i'ritothesaid grooves. A) 1 7, A l

An object of this invention is the provision of a tri- `angular-shape'd panel member having elongated grooves positioned on each of the panel vedges and on the panel virfenib'er faces parallel to the edges thereof, notches at "each'of`the sides of the panel members and comprising "ut-out portions at the edges and adjacent cut-out pori L """opposite panel faces extending the depth of aidig'ro ves, thelsai-d notches providing means wherein er`i'iemhers `in"ay be inserted into any of the said a ,ice

An object of this invention is the provision of a right isosceles triangular-shaped panel member having elongated edge groovespositioned on each side edge midway between the panel faces and elongated'fa'ce grooves von both of `the panel faces parallel to the edges thereof `a spaced distance therefrom, the said edge and face grooves being of substantially identical shape and including an enlarged bottom portion; and recessed portions inthe edge of the panel member on each side thereof and in both panel faces adjacent the said edge recessed portions, the said recessed portions providing means through which binder members are adapted to be inserted into the said grooves.

These and other objects and Vadvantages' will become apparent from the following dmci'iption when taken with the accompanying drawings. It ,will be understood the drawings are for purposes of illustration and are not to be construed as defining the scope or limits of the invention, reference being had for'the latter purpose to the appended claims.

`In the drawings wheein like reference characters denote like partsin the several views:

Figure 1 isa front view of two of our novel triangularshaped panel members, or building blocks, joined at adjacent short sides thereof;

Figure 2 is a front view of two panel members joined at the short side of one and the long 'side of the other;

Figure 3 is a front view of a plurality of panel members joined together to form anend wall and gable of a peaked roof building structure;

Figure 4 is a perspective view of a binder member for use in connecting adjoining panel members; l

Figure 5 Vis a fragmentary cross-sectional view of four attached panel members;

Figure 6 is a sectional View taken on line 6 6 of Figure 5;

Figure 7 is a sectional View taken on line 7 7 of Figure 5; j i` Figure 8 is a fragmentary cross-sectional view of iive (5) attached panel members;

Figure 9 is a fragmentary perspective VView of two attached panel members used "as a ilor and wall structure and showing an electrical cable positioned in a groove in the wall portion;

Figure 10 is a fragmentary perspective view of three (3) adjoining building blocks, two of which form wall members and a third which forms a oor member, and

showing a flexible canvas sealing member attached to the bottom of the floor member;

Figure 1l is a fragmentary perspective View of three v(3) panel-members used to form a double thickness oor and 'adjoiningwalh which are attached to a concrete base; Figure 12 is a fragmentary 'perspective 'View of two w'all'panel members attached to a concrete wall;v

Figure 13 is a fragmentary perspective view of a build-v Figure 17 "is a fragmentary perspective view oftwo `building blocks, joinedso as'toform'portions of a'p'eaked roof structure;Y and, Y

"Figure `I8 .is La' front 'View offfoiir building blocks s `ing various 'materials which 'may `b'e in the ostructinitheref `provided with elongated groove 30 which extend parallel with theside edges ofthe panel members. Identical shaped grooves (which are .not visible in Figure 1) are formed on each edge and on the opposite yfaces of the panel members. Recessed portions 31, which extend past the grooves,'are formed on each of the threesidesof the triangular-shaped panel vmembers; one recessed portion 31 being located on each of the short sides 23, 24 and 26, 27 and three recessed portions being located on each of the long sides 2S and 28 of the panel members. The recessed portions 31 on the short sides of the panel members are located at the center o f the sides. The central recessed portion 31 on the long side of the panel members is also located at the center of the long sides and, as will be clearly seen in Figure 2, the twov recessed portions on opposite sides of the central recess are located the distance of one-half the length of a'short side of a panel member from the ends of the long sides. (All of the dimensions are made from the center of the recessed po'rn tion.) The purpose of the vrecessed portions, and the reason for the location of the recessed portions will become apparent below. As seen in Figure 1, the two panel members 21 and 22 are joined together by binder members 33, portions of which` are visible at the recessed portions 31 in the short, adjoining sides 23 and 26 of the panel members. The binder members 33 are adapted to be inserted into the grooves in the panel members through the recessed portions. Details of the joint and recess construction are given below. y

Reference is now made to Figure'Z of the drawings wherein two panel, members 36 and 37are shown joined at the short side 38 and long side 39 of the respective members.- In FigureZ, it is seen that the recessed prtion 31a on the short side 3S of one panel member 36 is located directly opposite the recessed portion 31b in the long side of the other panel member 37 when the upper corners of the two panel members are at the same level. When recessed portions on adjoining panel members are positioned directly opposite each other, the two panel members-may be joined by binder members inserted through the recessed portions and into adjoining grooves on the panel members. In Figure 2, the panel members 36 and 37 are joined by binder members 33 which are passed through the recessed portions 31a and 31b and inserted into adjoining grooves in the panel members. It will be4 understood, however, that each of the edge grooves on the ypanel members extend the entire length thereof and, therefore, binder members may be inserted from`the ends of the grooves as well as through adjoining recessed portions, if desired. In the construction of building structures, however, the ends of the grooves on adjoining panel membersare not always accessible in which case binder members must be inserted into the grooves through adjoining recessed portions.

As mentioned above, the triangular-shaped panel members are preferably seven (7) feet in length on the short sides thereof. It will be apparent that several panel members may be joined together and used to form building components such as floors, walls, etc. In Figure 3, a plurality of such panel members are shown joined so as to form a building end wall and gable construction. Referring to Figure 3, four panel members 42, 43, 44 and 45 are shown joined together to form the end of the building structure; the resulting end wall being somewhat less than ten (10) feet square when the above-mentioned size panel members are used where theishort'sides are bers are of similar shape.

seven (7) feet in length. Two panel members 47 and 48 form the gable construction of the structure. The panel members 42 through 45 are joined together by binder members 33 which are passedthrough adjoining notches on the shortsides thereof and inserted into adjacent grooves at the panel edges. The gable panel members 47 and 48 are joined by the binder members 33 and, in turn, are attached to the long side of the panel member 43 by use of binder members 33b.

A perspective view ofa binder member 33 is shown in Figure 4. Referring Yto Figure 4, the binder member 33 is made with a 'substantially dumb-bell cross sectional shape comprisingenlarged edge portions 50 joined by a thin web portion 51. Obviously, the enlarged edge portions may be made of other shapes than the illustrated circular shape providing the grooves in the panel mem- The exact shape of the grooves and binder members 33 is not important,v so long as the grooves are provided with enlarged bottom portions which are adapted to receive enlarged edge portions von the'binder members. Thel binder member 3 may be made of metals, plastic, wood, hard rubber or any other .suitable material, andv may be sti or relatively flexible. If the binder members are made of stiff material, the length must be made slightly less than the length of va recessed portion 31 in the panel members in order that the binder member may be placed in adjacent recessed portions in adjoining panel members and slid longitudinally into the panel member grooves. If, on the other hand, the binder members are made of sulciently flexible material, they may be flexed enough to be inserted into the grooves through the recessed portions from outside of the recessed portions.

In Figure 5 of the drawings a fragmentary end view of a connection between four (4) building blocks 55, 56, S7 and 58 is'shown. Referring to Figure 5, the building block 55, which forms a oor panel member, is shown attached by means of a binder member 33 to the building block 56, which forms a wall panel member of a building structure. One enlarged edge portion 50 of the binder member 33 engages the edge groove 30a in the floor 1 panel member-55 while the other enlarged edge 5B engages the enlarged groove 30v in the face of the wall panel member 56. In this manner a rigid right angle'connection betweenthe panel members 55 and 56 may be made. Similarly, a binder member 33h connects a floor panel member 57 to the wall panel member 58; while a binder member 33a connects the two wall panel members 56 and 58 in an abutting edgewise relation. Each of the resulting corners between panel members is shown covered by a corner covering member `60 which may be attached to the panel members by means of short lengths of binder elements secured to the covering members which are inserted into grooves in the faces of the panel members. By way of illustration, the corner covering 60 between the wall panel member 56 and floor panel vmember 57 is attached by binder elements 62 (only the ends of which are seen in Figure 5) which are integrally formed on the corner cover and which are inserted into the grooves 30b and 30C in the wall and oor panel members, respectively. Also, the grooves in the panel members may be used to support electrical cables, and the like. In Figure 5, a cable 64 is shown extending between the groove 30e in the oor panel member 55 andthe groove 30d in the wall panel member S8 at a recessed portion in the panel members.

It is seen that the fragmentary sectional view of Figure 5 is taken at recessed portions in the connected panel members; the recesses in the panel members 55, 56, 57 and 58 being designated generally 31a, 31b, 31e and 31d respectively. All of the recessed portions are of identical shape; each comprising three cut-out portions one cutout portion 66 at the edge of the panel members and two cut-out portions 66a and 66h, one on each face thereof. (For clarity in the drawing, only the floor panel member 57 is provided with reference iimeralsdes'i'gatiig the three-cut portions 66, 66a and 66b, 'the 'exitout 'poi'- vtions on therother panel members being clearlyshown in the drawing.) "It is seen that all of the grooves 30,6041,

31th etc., in each of the panel members 55 through lS8 fare accessible through the recessed portions when the lcorner` (`)"v`er`iiigs "60 are removed. To join any two vpanel'members with ajbirider member, the recessedpor.- 'tions in adjoining panel members are placed adjaeent 'each other, the binder Vmember placed in the `recessed lportion, aligned with the adjoining grooves, and inserted intieme gmVS long itidinally thereof. Obviously, it the ends f'hgfOOVSfS in the panelmembers are accessible,

bindet-members may `bezinserted in the 'grooves from the "ends ofthe panel members without use or benefit of the recessed prtions in tbe panel members.

Reference Ais now made to Figure V6 of the drawings whereinfthere is shown a sectional' View` taken en line t'6 116 ,jef Figure 5. nl AFigure 6, portions" or the binder members '33a which join the panel members 56 and '58, visible in the recessed portions 31h and 31d `in the `l rnembe'rs 56z`fand 58, respectively. The binder members 33a are of 'the usual type comprisingenlarged ed'geportions` Sile which' arejoined bya thin web por- 51h. The binder members 33, which join V4the door .panel member `55 tothe wall panel member S6, Aare positioned above the binder members 33a. The `entire of are ammiratori. met entity 'in the arrange,

y 'the panel members 72 and 74er Figure-f8 will be r plied vwith further reference numerals employed inthe following description of the panel construction. -lt vn'll b'e`^rioted that in the fragmentary sectional view of Fig- "tire the section through the panel member 72 passes through a recessed portion while the section through the panel member 74 does not.) VEach panel member comprises three frame members`78 (sections of lonly one ofthe trame members for tbepanel members 72 and 74 beingvisible in the fragmentary view of Figure 8) which are joined so as to form an isosceles right tri- "angle framework. Each frame member 78 contains the `usii'l fedge groove 79 and race grooves b1. The triangular-shaped framework of frame members 78 may be enclosed withI panel portions 82.

The `frame members 78 may be manufactured by an `extrusion process if suitable material, such as metal or plasticfis used.' By eXtruding the framemembers, ma-

chining/of the frame members is reduced to a minimum 'thereby resulting in an economical framework construc- 'tidrn The recessed lportions in the frame members are 'erossisectional length or the web portions 51v of thej binder members 33 are visible, while only those portions 'he'enlarged edge portions E@ which `extend 'intthe ss 3119 may be seen. The cable 64 extends yfromthe,

"g ooveidd at the 'lettside of the recessed portion 31dE R verence is now made "to 'Figur`e`7 ofthe drawings if herein `a v'sectional view 'taken'on theV line 7-`7 Hof Figure 5 is shown. In Figurei7`the bindermemb'ers 33a l vvhicri Vjoin the panel members ,56 and S8 arel shown ,broken away at several places." The edge grooves inthef` paa members st and saf'io'gthe rea amtrighteoflthe cessed portion, are indicated generally 4by reference ral 69. The yreference"numeral 69a (whereone of tb binder members is shown broken away) designates 'an'area where a section rof the panel members 56 and havebeen removed to form part of the recessed por- 'tirs 31b and 31d, respectively.

A floor V and wall 'construction which i`s `'somewhat lsimilar to that shown in Figure 5, is shown in'Figure 8. e` construction shown in Figure 8 however," inclu des lafdinfuble thickness -wall portion. Referring to Figure' 8,

Ithen iit'to thedepth ot' the groove'deptlts as shown in the view of the `frame member 78 which forms a part of the panel member 72. A rectangular-shaped rib 83 ults at the recessed, or cut-out, portions' of the frame fr'neiber., The frame members 7d are also provided with flange members 34 which'are adapted to closely t in elongated notehes 86 in the panel `portion 82 of the panel members. The frame members 78 are not excessively weakened by the recessed portions as the 'rib 83 and flanges 84provide the necessary strength thereat.

` Reference will now be made 'to Figures`9 through 1'7 wherein several of the many possible constructions employing our novel panel members are shown. Referring first to Figure 9, a floor panel member 8S is "shown joined v to a Wallpanel member 39 by a binder member v91. The

panelmembers 70, 7 1, '72 and v73 are joinedv bythe binder members 33, 33a and 33h in a manner similar t; `'the connections b e'twe'enwthe panel members S5, 5 6, v ;afand 58 of Figure `5. In Figure 8, however,` a double thickness wall portion is kformed by the inclusion of the panel member 74 whichii's attached to the oor panel i `niernb-=r 72 by means of a binder member 33e, and is in `a juxtaposition with the wall member 73. A iloor edging l'irfember176; which is provided 'with an enlarged edge vpbrtin 762i which sinserted in a groove in the oor panel member 7d, covers the joint between the wallv and oor-panelmembersl' and 7i), respectively. The connections betweenthe panel members may be strengthened by the use of W-shaped binder members 77 which 'fare sliownfpositioned between the door panel member lvnvpv'nel member '71"and floor panel member 72. The

W-shaped binder members are provided with the usual enlarged edge portions which are adapted to slidably engage the grooves in the panel members.

It may here be noted that the panel members of our invention may be made of any suitable material such as metal, plastic, wood and the like;` which material has door 'panel 88 is provided with `a floor covering 92 which is securely attached thereto by means of binder elements 93 'which fit in a face groove in the floor panels. Added rigidity may be secured by positioning a binder -element 94A 'of ygenerally' "U-shape construction, in grooves Vin the bottom face `of 'the lloor panel 83 and the right side face i of-the panel 89.. An electrical conduit 96 extends Ythrough -the edge groove of the wall panel member 89.

Referring now to Figure l(),vwal1 'panels'V 98 and 99 are yshown joined by a bindery member 101 and a `U- 'shaped binder member 102. A iloor panel yrneriber'lll is 'secured to the wall panel 'member 99 with the binder `member 104, and'to the panel mermberf9h8 with a binder i member 106 which is provided with oit-set end portions K"107. (All of the binder members are provided with the usual enlarged edge portions which engage kenlarged rgroove'bottoms in the various panel members.)v tIffrgie- "sired,a .exible canvas memberi108 maybe `attached to the bottom face groove of the door panel member y102 and permitted to' hang vadjacent the wall panel niember 99Vf y 1Q.'

Y In Figure 11. of. the drawings a double thickness door unit is shown.' Referring to Figure 1 1,` a trstoor panel member 1 09 is shown secured byuse of'a binderlrnember 111'to a wall panel member 112.` A double' layer Hc'mrunit is obtained byl'securing a seeond floor panel member 113 t0 "Phe'rst iloor panel k'Arriember 199 bylfa binder'member 114. The floor` panel member'109and wall panel member 112 may be securely anchored to a concrete base 115 by means of binder members 117 and suicient strength and rigidity for the structural use for which it is intended. One possible panel member construction is illustrated by the panel members in Figures 5 and 8, all of the panel members shown therein being Igesamt-s novel panel members may be made by the construction embedded in a concrete base 128 whereupon a permanent y connection results. A further concrete to panel member fastening arrangement is illustrated in Figure 14 of the drawings. Referring to Figure 14, two attached floor panel members 130 and 131 are shown attached to a concrete base 132 by means of binder members 133.

Reference is now made to Figure 15 of the drawings wherein a frame member 134 of a panel member 136 is shown provided with a decorative pattern 135. It is seen from Figure 15, then, that the esthetic appeal of a building structure composed of decorated panel members is greatly increased. Also illustrated in Figure 15 is a floor panel member 137 which is of one-half the thickness of the ordinary panel member thickness. The panel rnernber 137 is bounded by layers 138 which terminate in enlarged binder elements 139 which are adapted to be inserted into grooves in the wall panel member 141 in the usual manner. l

A novel side lwall to roof construction is shown in desired angle between the roof panel member 143 and wall panel member 142. The edges of the binder members are provided with the usual enlarged portions which shallv fall within the spirit and scope of the invention as recited in the following claims.

' We claim.

1. Atriangular-shaped panel member having elongated grooves positioned on each of thepanel member edges and on the panel member faces parallel tothe edges thereof, the said elongated -grooves havingk enlarged bottom portions and being adapted to receive binder members longitudinally thereof, and recessed portions at each of the threesides of the triangular-shapedpanel member, each recess comprising adjacent cut-out portions at the edge and opposite panelfaces, the said recessed portions providing means through which bindermembers may be inserted into any of the said elongated grooves. Y 2. The invention as recited in claim 1 wherein the said cut-out portions extend toa depth of the depth of the said elongated grooves.

' 3. The invention as recited in claim 1 wherein the said panel member is of an isosceles right triangular-shape and a recessed portion is located at the centerof each of the sides thereof and on opposite sidesl of the Center recessed portion on the long side of the panel member av distance of one-half the length of a short side of the panel member from each end of the long side thereof.

4. A structural member comprising a triangular-shaped framework, the said framework comprising frame members having elongated grooves positioned on each outside edge and on opposite faces parallel to the edges thereof,

yare adapted to be positioned in grooves in the panel mem- A bers as illustrated. An ea-ve trough 147. may be secured to the roof panel member 143 by use of binder elements 148 suitably attached to a supporting arm 149 on the eave trough, and inserted in a groove on the roof panel ,member 143. r i

vIn Figure 17 of the drawings two panel members v151 and 152 are joined by binder members 153 and 154in a manner somewhat similar to the connection of thek panel members 142 and 143 of Figure 16. In Figure' 17, however, the panel members 151 and v152 form roof `memtion by binder elements 157 secured thereto and inserted in the grooves on the side ofthe panel members 151 and 152 in the usual manner.

- Reference is now made to Figure 18 of the drawings wherein four panel membersl (or building blocks) 160, 161, r162 and 163 are shown joined together. Each of the panel members comprises a triangular-shaped framepanel members 161 and 163. Alternatively, the panel membersmay be made of the screened type as shown by ance with the patent statutes, variousV changes and modications will suggest themselves to those skilled in this art, and it is intended that such changes and modifications work composed of grooved and'recessed frame members. i The frameworks may be left open as illustrated by the the said elongated grooves having enlarged bottom portions and being adapted lto receive binder members longitudi'nally'thereof, and notches at each of the'three sides of the triangular-shaped framework, the said notches eX- tending substantially the same depth as the depth of the said grooves and communicating with the grooves, the said notches providing access ways through which binder members may be inserted into the said elongated grooves.

5.. A structural panel member having parallel face portions adjacent the edges thereof, each of the edges having elongated grooves therein positioned midway between the [said elongated grooves having enlarged bottom portions and being adapted to receive binder members longitudinally thereof, and a recessed portion at the grooved side of the panel member, each recess comprising adjacent cut-out portions at the edge and opposite panel faces, the said recessed portions providing means through which binder members may be inserted into any of the said elongated grooves.

7 The invention as recited in claim 6em/herein the said Acutout portions extendto adepth of the depthof the Ysaid elongated grooves.

References Cited in the file vof this `patent UNITED STATES PATENTS Auen 'Dee 24, I1940 Eichelberger L `Nov. 21, 1944 2,440,449 Raemer Apr. 27, 1948 

